A major poultry processor and packager spends an estimated $96,374 annually on energy to operate the compressed air system at its plant located in a southern U.S. state. The current average electric rate, at this plant, is 8 cents per kWh.
The 2017 International Production & Processing Expo (IPPE) had a great year with 31,649 poultry, meat and feed industry leaders from all over the world in attendance, setting a new record. There were also 1,273 exhibitors with more than 533,000 square feet of exhibit space, another new record. The Expo is the world's largest annual feed, meat and poultry industry event of its kind and is one of the 50 largest trade shows in the United States. IPPE is sponsored by the U.S. Poultry & Egg Association, American Feed Industry Association and North American Meat Institute.
A small Australian company, Basil V.R. Greatrex (BVRG), is shaking up the compressed air industry in Australia. While other companies focus on the sale of more and bigger compressed air production equipment, BVRG is helping customers reduce their compressed air system size and lower system flow by attacking waste, inappropriate use, and at the same time improving air quality.
The useful and various properties of nitrogen (N2) in industrial applications rank it as one of the most specified gases in industry. For the manufacturer, nitrogen options exist in the choice of delivery system, compliance with clean air standards, safety and purity. In researching these choices, manufacturers can accurately select the optimum nitrogen supply required, often at a considerable savings. Selecting purity levels of 99.99% or higher in many industries and applications ads a variety of costs, both financial and efficiency, which may be needlessly incurred.
Made from various combinations of hops, grain, yeast and water, beer is a drink that has been produced for centuries. But while the ingredients are simple, the chemical processes behind the drink are anything but. Through various reactions, barley becomes fermentable sugars that are then digested by the active yeast to produce carbonation and alcohol. Although the basic principles behind brewing are little changed since their advent, the technological aspects are much improved. Today, large stainless steel tanks are used for fermentation and wort aeration, and complex, automated systems help with everything from temperature regulation to bottling.
Imagine a dairy farm. Do pictures of idyllic pastures populated by grazing, happy cows come to mind? What about the not-so-idyllic image of farmers milking cows by hand? Modern dairy farms work a little differently. Darigold, a farmer-owned dairy co-op located in the Pacific Northwest, has the happy cows, but production is more sophisticated. The company has eleven state-of-the-art production facilities churning out high-quality dairy products at mind-boggling rates. Milk, for instance, is produced to the tune of 2.6 million gallons per day. To maintain efficient production at scale, Darigold also has an innovative energy management program in place.
To produce healthy, high-quality cooking oil, this food processing company crushes and processes oil seeds shipped in from local farms. The oil produced is thought to be the healthiest cooking oil available, because it is low in saturated fat, high in monounsaturated fatty acid (MUFA), and polyunsaturated fat (PUFA), like omega-3 fatty acids. To increase the energy efficiency of its oil seed crushing and processing facility, the company optimized its compressed air system by combining three separate systems into one. Some end-use optimization was done to correct low pressure, particularly caused by some critical high-flow, short-duration events.
According to the Compressed Air and Gas Institute (CAGI) and the International Organization for Standardization (ISO), the three major contaminants in compressed air are solid particles, water, and oil. CAGI promotes proper use of air compressors with various educational tools, while ISO 8573 is directed at the very specific areas of compressed air purity and test methods, which this article will address. Microorganisms are also considered a major contaminant by CAGI, but will not be discussed in this article.
Health and safety issues are a major concern in the food industry. Not only can contaminated food products endanger consumers, but they also can cause significant damage to a company’s reputation and bottom line. Contamination can come from many sources—industrial lubricants among them. With the abundance of lubricated machinery used in the food industry, lubricant dripping from a chain or escaping through a leak in a component can prove catastrophic. Even with the most prudent maintenance and operating procedures, along with a strict HACCP (hazard analysis and critical control points) plan, contamination may still occur.
In the food and beverage industry, the moment a product leaves the production line, the clock starts ticking down to when that product will no longer be viable for sale or consumption. To combat the clock, modified atmospheric packaging (MAP) techniques are used to help maintain product freshness and increase shelf life. Nitrogen is the most cost effective, efficient and widely used industry solution for a company’s packaging needs—whether it is for manufacturing cheese, coffee, dried snack foods, or fresh and ready-to-eat (RTE) foods. MAP also helps to decrease chances of contamination or spoiling, keeping products on the market for longer and ultimately increasing the reach of distribution.
Technological trends in plastics manufacturing are driving the costs of production down. In industrial PET blow molding specifically, two innovative techniques have had major impacts over the last 15 years: “light weighting” the plastic bottles, and recirculating high-pressure compressed air. Both have helped to improve the energy efficiency of PET blow molding by reducing compressed air requirements dramatically.